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EP1070243B1 - Verfahren zur automatischen inspektion optisch transparenter planarer gegenstände - Google Patents

Verfahren zur automatischen inspektion optisch transparenter planarer gegenstände Download PDF

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Publication number
EP1070243B1
EP1070243B1 EP99915261A EP99915261A EP1070243B1 EP 1070243 B1 EP1070243 B1 EP 1070243B1 EP 99915261 A EP99915261 A EP 99915261A EP 99915261 A EP99915261 A EP 99915261A EP 1070243 B1 EP1070243 B1 EP 1070243B1
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EP
European Patent Office
Prior art keywords
camera
light
mask
stripe
clear
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP99915261A
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English (en)
French (fr)
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EP1070243A1 (de
Inventor
Peter Winston Sites
Anthony Scott Nelms
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Northrop Grumman Corp
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Northrop Grumman Corp
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
    • G01N21/896—Optical defects in or on transparent materials, e.g. distortion, surface flaws in conveyed flat sheet or rod

Definitions

  • the invention in general relates to inspection systems and more particularly to a system which automatically inspects planar objects to determine various defects.
  • some manufactures utilize machine vision technology whereby the assessment is done automatically using digital video cameras for image capture and image processing for defect determination. This process is a significant improvement over the human operator method, but is still not capable of properly or sufficiently enhancing the entire range of defect types.
  • the present invention provides greater sensitivity to defect detection and is capable of detecting a greater range of defect types.
  • a method of detecting defects in a transparent sheet is disclosed in EP-A-0 576 011 , according to which light is directed through a slit screen having alternating light shading and transmitting portions and thereafter through a transparent sheet to a camera.
  • the camera is arranged to have a focal plane at a relatively large distance either in front of the transparent sheet or behind the screen. Detection of e.g. dirt on the transparent sheet is thereby avoided.
  • a further method of detecting defects in transparent sheets is disclosed in EP-A-0 726 457 , according to which light is directed through a slit screen having alternating light transmitting and shading portions and thereafter through a transparent sheet to a camera.
  • the camera is provided having a focal plane at a point of uniform light intensity located neither on the slit plate nor on the transparent sheet. The influence of e.g. a particle of dust on the surface of the transparent sheet thereby does not influence the image obtained.
  • a method for detecting defects in optically transmissive planar objects utilises an apparatus including a camera for obtaining images of the object and a light source positioned to direct its light toward the camera.
  • An object inspection location is disposed between the light source and camera for receiving the object, or a portion thereof, to be inspected.
  • a mask is positioned between the light source and inspection location, with the mask having either a) a narrow clear stripe, for allowing transmission of the light, and straddled by opaque regions which block transmission of the light, b) a narrow opaque stripe straddled by clear regions.
  • Means may be provided for relatively moving the object through the inspection location during which time the camera is operable to obtain an image of the object.
  • a processing arrangement is provided for processing the obtained images for providing indications of predetermined defects in the objects.
  • Fig. 1 illustrates a transparent sheet 10 representative of rigid sheet glass or plastic, as well as relatively thin plastic wrap.
  • Fig. 2 is representative of an optical flat 12 which may be used in the fabrication of eyeware, filters, or optical instruments such as telescopes, etc.
  • Fig. 3 is representative of an intraocular lens (IOL) 14.
  • the IOL 14 includes a non-optic portion in the form of a planar flange constituting what is known as a haptic zone 16.
  • Anchor holes 17 secure the IOL to the interior of the eye.
  • the inspection of the lens portion of objects such as the IOL is more fully described and claimed in commonly assigned copending application serial number 08/995,081, filed December 19, 1997.
  • the present invention is applicable for the inspection of the haptic zone of such IOLs.
  • the apparatus employed in the method of the invention may include a digital video camera 20 having an optical axis 21.
  • the camera 20 views an inspection location 24 through which passes an object to be examined for defects.
  • the object is, by way of example, a glass or plastic sheet 26 which is moved on rollers 27 by a drive mechanism 28.
  • a light source 30 Positioned on the other side of the inspection location 24, and along the optical axis 21 of the camera 20, is a light source 30 which in the preferred embodiment, provides a diffuse light. Light from this source 30 passes through a mask 32, having a particular design, as will be described, such that an image is captured by the camera 20.
  • a signal processor 36 is operable to take a captured image and perform various diagnostic routines well known to those skilled in the art, to determine the presence of a multitude of possible defects using images obtained with the mask 32 in position. These images may, if desired, be displayed on a high resolution display 38.
  • a personal computer 40 may be included and allows for operator interaction with the signal processor 36 to enter data such as object lot number, camera settings, and to obtain information on defects, product runs, and summaries, by way of example.
  • the optics and settings of the camera 20 are such that it examines a viewing area 42 on the object 26. After an image of this area is captured, the object may be indexed by the drive mechanism 28, under control of processor 36, such that a new area of the object is brought to the inspection location 24. If desired, a shaft encoder 44 may be included for providing positional information to the signal processor 36. Other drive means for bringing an object, or a pallet carrying the object, to an inspection station may be utilized. One such arrangement, for examining IOLs, is illustrated in the aforementioned application.
  • the optical axis 21 of the camera 20 lies along the Z axis
  • the object is moved along the X axis
  • viewing area 42 lies in an XY plane.
  • multiple cameras with light sources and masks may be provided for the entire width of the object, in the direction of the Y axis.
  • the sensor array 50 located in the camera 20 is constituted by an XY array of individual identical sensor elements 52, such as CCDs.
  • CCDs Compact Discs
  • Commercially available digital video cameras have sensor arrays which typically range from 1024 x 1024 elements to 4096 x 4096 elements, depending upon the resolution desired.
  • a light source arrangement is incorporated which provides diffused light for the object examination.
  • Figs. 6A and 6B serve to illustrate this concept.
  • a light source 54 projects light through a clear plate 56.
  • a single ray of light, as represented by arrow 58 passes through the clear plate 56 and emerges as a single ray 58'.
  • a similar light source 60 projects light through a diffuser plate 62 and a single ray of light, as represented by arrow 64 emerges from the diffuser plate 62 as a plurality of rays 64' emerging in different directions and with different intensities, depending upon the type of diffuser plate utilized.
  • the diffuser plate may be placed over the light source, or, as utilized herein, may be integral with the masks that are used.
  • a transition mask 32 is composed of alternate bands of clear (light transmitting) and opaque (light blocking) portions. In one embodiment these alternating bands take the form of parallel stripes as illustrated by transition mask 32 in Fig. 7, with opaque stripe portions 70 and clear stripe portions 72 being positioned upon a diffuser plate 74.
  • the light source 30 When using this transition mask, the light source 30 will be of the type which provides a monochromatic light.
  • the nature of the transition mask is such that the diffused monochromatic light from the clear stripes 72 between the opaque stripes 70 interact in a constructive and destructive manner at different distances from the mask.
  • the combination of light source 30 and transition mask 32 will produce a cyclical pattern going from stripes to a uniform pattern, as a function of distance. This is shown for two different distances D1 and D2. At D1 the pattern is comprised of distinct stripes, while at distance D2 the pattern is essentially uniform.
  • the camera 20 positioned along the optical axis 21 can be focused to an object plane where the pattern of constructive and destructive light rays will show up, at the camera image plane (where the CCD array 50 is located) as a striped pattern, as an essentially uniform pattern or somewhere in-between, depending on the position of the camera along the optical axis.
  • the light striking the CCD array of the camera 20 must be monochromatic light such as may be provided by a monochromatic light source or by an appropriate filter positioned on the optical axis.
  • curve 76 represents the intensity of light with respect to lateral distance, at one point along the optical axis.
  • the positive peaks 78 of curve 76 represent maximum intensity and are indicative of clear stripes, whereas the negative peaks 79 represent minimum intensity and are indicative of dark stripes.
  • the transition from clear to opaque stripes is represented by the sloping portions 80 of the curve and it is in this region that defects are most pronounced.
  • Curve 76' shows the intensity at still another location, whereas the horizontal line 82 represents an essentially uniform pattern at some other position.
  • the transition mask is especially well adapted to detect various subtle defect types such as flow marks, warpage, scratches, embedded inclusions and small surface voids which are not detectable by other inspection techniques.
  • the apparatus takes advantage of the constructive/destructive interference effect as described in Fig. 8.
  • the camera 20 is focused on an object plane 84 at which an essentially uniform image of the striped pattern exists - (one uniform image being illustrated at a distance D2 from the light source in Fig. 8).
  • the object 10 can now be inspected against a uniform background while still maintaining sensitivity to subtle defects.
  • the object is displaced above the object plane 84 by a small distance d (or a small distance below the object plane).
  • Fig. 10A the lens system of the camera 20 is represented by lens 88. Rays 90 and 91 emanate from point A, at the boundary between a clear and opaque stripe on the transition mask 32. These rays, which at the object 10 are designated as A', strike the lens 88 and are imaged at point A' ' on the sensor array 50.
  • a defect in the object 10 is present, such as at point X in Fig. 10B, it will cause a ray from point C which would normally be imaged at point C" to be redirected, as indicated by the dot-dashed ray 96, to a point C'" on the sensor array 50 causing a disruptive influence on the otherwise uniform image.
  • the redirection of light is optimized by the alternating clear and dark stripe pattern because all defects are in close proximity to an opaque/clear boundary. In this regard, the stripe spacing is selected to be small to maximize this effect.
  • a transition mask 32 located 70 mm behind the object, may have a dimension of 40 mm by 40 mm with a stripe spacing of less than 1 mm, for example 0.5 to 0.8 mm.
  • the distance d may typically be around 4 mm.
  • Fig. 10C illustrates another mechanism which causes an image shift.
  • the object 10 to be inspected includes a defect 100 in the form of a protrusion essentially equivalent to a small lens having its own optical axis different from optical axis 21 of the camera 20.
  • Rays 102 and 103 emanate from point A on the transition mask 32, proceed through object 10 ,and are imaged at point A'' on the sensor array 50.
  • the defect 100 forming a small lens causes rays 104 and 105 emanating from the same point A on the transition mask 32 to proceed to point A'" on an image plane 108 of lens 100 and which image plane is skewed with respect to the image plane defined by the sensor array 50, resulting in detail shifts.
  • Fig. 11 illustrates the invention.
  • the embodiment of Fig. 11 is more sensitive to defects and is somewhat easier to implement, set up and maintain than the embodiment of Fig. 4. It is also less sensitive to variations in camera distance and mask distance from the object being inspected.
  • Fig. 11 many of the components of Fig. 11 are similar to those of Fig. 4, however the camera 110 in the embodiment of Fig. 11 is a line scan camera having an optical axis 111. This camera obtains an image of the object being tested, one line at a time and thus the viewing area 112 for camera 110, at inspection location 24 is a single line.
  • the mask 114, illuminated by light source 116 is comprised of a single stripe, as will be described.
  • the light source 116 may be of the type which provides a conventional light or may be of the type which provides a monochromatic light.
  • a mask 114 located 50 mm behind the object, may have a stripe width of around 1.75 mm and a length equal to or greater than the 256 mm width being examined.
  • Fig. 12 illustrates the sensor array 120 of camera 110.
  • the sensor array 120 is a straight line array of individual sensor elements 122, typically ranging, in a commercially available camera, from 256 to 4096 CCD sensor elements, depending upon the resolution desired.
  • Figs. 13A and 13B Light masks for this embodiment of the invention are illustrated in Figs. 13A and 13B.
  • the mask 114 is on a diffuser plate 126 and is comprised of an opaque stripe 128, which blocks transmission of light, with the opaque stripe 128 being straddled by clear regions 129 which allow transmission of light.
  • mask 114' in Fig. 13B is comprised of a clear stripe 130 which allows transmission of light, straddled by light blocking opaque regions 131.
  • the stripe in the two different mask patterns will be the region observed by the line scan camera 110 when no object is present for inspection.
  • the image of the object being inspected will have a black background in which any defects will show up as white.
  • the image of the object being inspected will have a white background in which any defects will show up as black. This may be observed with reference to Figs. 14A, 14B and 15A, 15B.
  • defects are enhanced based upon an optimized dark field technique for which a dark field boundary between opaque and clear is always in close proximity to the defect in question.
  • defects are enhanced based upon an optimized bright field technique for which a bright field boundary between clear and opaque is always in close proximity to the defect in question. Both of these require light to be redirected only a slight amount by a defect in order for it to be detected.
  • Fig. 14A illustrates the use of an opaque stripe mask 114.
  • the camera 110 having a lens system represented by lens 134, is focused at the object plane 136.
  • the object 10 is positioned at the object plane 136, as opposed to above it.
  • ray 141 from point B passes through object 10 at point B' and is imaged at point B" at the sensor array 120.
  • a ray such as ray 142, from point C does not enter the camera, or if it does, it is at an angle which does not result in its being imaged at any sensor element.
  • Fig. 14B illustrates the object 10 with a defect 144.
  • Rays 140 and 141 from points A and B are imaged as before, however the ray 142 from point C rather than continuing as before (indicated by the dot dashed line 142') is now redirected by the defect 144 so as to be imaged at point C" on the sensor element, causing its output to vary from a signal which previously represented a completely dark area, to a signal which now represents a lighter area, due to the contribution of light from point C.
  • Figs. 15A and 15B illustrate the concept utilizing a clear stripe mask 114' .
  • boundary rays 146 and 147 from respective points A and B of the mask 114' pass through the object 10 at points A' and B'. These rays are directed to sensor array by the lens 134, where they are imaged at respective points A" and B". Any ray emanating from the clear stripe 130, such as ray 148 from point C will also be imaged at the sensor, as represented by point C", and thus the sensor element will provide an output signal indicative of a bright area.
  • Fig. 15B illustrates the object 10 with a defect 150.
  • Rays 146 and 147 from points A and B are imaged as before, however the ray 148 from point C rather than continuing as before (indicated by the dot dashed line 148') is now redirected by the defect 150 so as to completely miss the sensor element, causing its output to vary from a signal which previously represented a completely bright area, to a signal which now represents a darker area, due to absence of the contribution of light from point C.
  • Figs. 16A and 16B illustrate images obtained utilizing the transition mask of Fig. 7 with the planar haptic zone of an IOL (Fig. 3) being inspected. These displays show the essentially uniform background 154 upon which the camera is focused and reference numeral 156 is a vacuum pick up device for holding the IOL in the inspection location, as described in the aforementioned application.
  • Fig. 16A illustrates typical flow mark defects and Fig. 16B illustrates a typical pit defect.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
  • Investigating Or Analysing Materials By Optical Means (AREA)

Claims (6)

  1. Verfahren zum Bestimmen von Defekten (150) in einem optisch durchlässigen ebenen Objekt (10, 12, 16, 26) unter Verwendung einer Vorrichtung, die umfasst:
    - eine Kamera (20) mit einem Sensorarray (50) zum Erhalten von Bildern des Objekts (10), wobei die Kamera eine optische Achse (21) aufweist;
    - eine Lichtquelle (30), die ausgerichtet ist, um Licht auf die Kamera (20) längs der optischen Achse (21) zu richten;
    - einen Objektinspektionsort (24) zur Aufnahme des Objekts (10), welcher angebracht ist zwischen der Kamera (20) und der Lichtquelle (30);
    - eine Maske (32), welche einen Streifenaufbau aufweist, der ausgewählt ist aus der Gruppe, die besteht aus (a) einem schmalen klaren Streifen (130), welcher den Durchlass des Lichts erlaubt, und eingeschlossen ist durch lichtundurchlässige Bereiche (131), die den Durchgang des Lichts blockieren, und (b) einem schmalen lichtundurchlässigen Streifen (128), der eingeschlossen ist durch klare Bereiche (129);
    - Mittel zum Verarbeiten der Bilder, um Hinweise auf die Defekte zu erhalten;
    wobei das Verfahren folgende Schritte umfasst:
    - Platzieren des planen Objekts (10) in einer Objektebene (84), welche die Ebene ist, auf die die Kamera fokussiert ist;
    - Positionieren einer der ausgesuchten Masken (32) im Lichtpfad zwischen der Lichtquelle (30) und dem Inspektionsort (24);
    - Bedienen der Kamera (20), um ein Bild des Objekts (10) mit der Maske (32) an ihrer Position zu erhalten, wobei die Kamera (20) auf die Objektebene (84) fokussiert ist.
  2. Verfahren nach Anspruch 1, wobei:
    (A) die Lichtquelle (30) monochromatisches Licht bereitstellt.
  3. Verfahren nach einem der Ansprüche 1 bis 2, wobei der Apparat umfasst:
    (A) Mittel (27, 28) zum Bewegen des Objekts (40) an den Inspektionsort.
  4. Verfahren nach Anspruch 1, wobei:
    (A) die Maske (114) entweder aus dem klaren Streifenaufbau oder dem lichtundurchlässigen Streifenaufbau (128, 130) besteht;
    (B) die Kamera (110) einen Sensor (120) umfasst, der ein Zeilenarray von Sensorelementen (122) aufweist, um ein Zeilenbild zu erhalten;
    (C) wobei die Vorrichtung Mittel (27, 28) umfasst zum kontinuierlichen Bewegen des Objekts (10) durch den Inspektionsort (24), um ein Bild des Objekts (10) aufzubauen.
  5. Verfahren nach Anspruch 4, welches umfasst:
    (A) Kodiermittel (44), die an den Signalprozessor (36) gekoppelt sind, um den Signalprozessor mit Positionierungsinformationen relativ zu dem Objekt (10) zu versorgen, während das Objekt durch die Inspektionsstation (24) bewegt wird.
  6. Verfahren nach Anspruch 4 oder 5, wobei:
    (A) das Zeilenarray (120) eine gerade Zeile bildet.
EP99915261A 1998-04-06 1999-04-05 Verfahren zur automatischen inspektion optisch transparenter planarer gegenstände Expired - Lifetime EP1070243B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US09/055,536 US6011620A (en) 1998-04-06 1998-04-06 Method and apparatus for the automatic inspection of optically transmissive planar objects
US55536 1998-04-06
PCT/US1999/007423 WO1999051971A1 (en) 1998-04-06 1999-04-05 Method and apparatus for the automatic inspection of optically transmissive planar objects

Publications (2)

Publication Number Publication Date
EP1070243A1 EP1070243A1 (de) 2001-01-24
EP1070243B1 true EP1070243B1 (de) 2007-08-22

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US (1) US6011620A (de)
EP (1) EP1070243B1 (de)
AT (1) ATE371185T1 (de)
DE (1) DE69936914D1 (de)
WO (1) WO1999051971A1 (de)

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ATE371185T1 (de) 2007-09-15
WO1999051971A1 (en) 1999-10-14
EP1070243A1 (de) 2001-01-24
DE69936914D1 (de) 2007-10-04
US6011620A (en) 2000-01-04

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